Weldable insulated panel seam

ABSTRACT

An insulated panel ( 10 ) is configured to be welded to another insulated panel ( 12 ), defining a seam with weld material ( 14 ) therebetween. A space or spacer ( 26, 28 ) is incorporated into each panel ( 10, 12 ) adjacent the seam so that the welding process can occur without damaging the insulative core ( 24 ) of the panel ( 10, 12 ) and offgasing does not occur from heating of the insulative core ( 24 ).

FIELD OF THE DISCLOSURE

[0001] The present invention relates to wall, ceiling, or floor structures comprising a plurality of insulated panels joined together to form an enclosure, and more particularly to a method and structure for welding a joint of metal skins of adjacent panels to provide a sealed enclosure.

BACKGROUND AND SUMMARY

[0002] It is conventional to provide insulated enclosures by assembling together a plurality of ceiling, wall, and floor panels with gaskets or caulking between adjacent panels. While such gaskets or caulking works for various applications, it is desirable in many applications to have a sealed interior in an enclosure which is illustratively provided by welding the inner and/or outer metal skins of adjacent panels together. It should be noted that although the following description discloses embodiments having the inner metal skins welded, it is within the scope of the disclosure to utilize embodiments having the outer skins welded either in addition to the inner skins, or instead of welding the inner skins.

[0003] It is desirable to ship these panels made in a factory to an installation site and to weld the panels on that site. Prior efforts to weld the metal skins together on the installation site have created problems with the welding process unduly heating the insulative core. The welding process has produced offgasing of materials that safety personnel have found objectionable and in violation of safety codes. Typically the insulative cores are some type of organic insulation material, particularly a cellular foam material such as polyurethane foam or polystyrene foam. When the welding occurs in close proximity to such materials, the offgasing or vapors produced by the welding are deemed objectionable or hazardous. Further, the insulative material in the area of the weld could ignite, presenting a further hazard.

[0004] In accordance with illustrative embodiments of the present invention, each panel is provided with an inner metal skin, an outer skin which may be metal, and an insulative core material sandwiched between the skins. Each panel provides a side edge portion which is configured to abut against the side edge portion of an adjacent panel. When two panels are placed together with their side edge portions in an abutting relationship, the insulative cores provide a thermal barrier at the point the panels abut. The inner metal skins of the adjacent panels are held in close proximity to be sealed. These inner metal skins may be abutting together or be spaced apart a small gap up to, for example, 0.125 inch (0.317 cm).

[0005] It has been found that these metal skins, when held adjacent each other, can be welded together by conventional TIG or MIG welding techniques. Typically, an inner metal skin will be a 16 gauge (0.060 inch (0.152 cm) thick) 300 Series stainless steel sheet. Such inner metal skins may be thinner or thicker depending upon the application. Such 300 Series stainless steel skins may be welded together when they are in actual contact, or when a small gap such as {fraction (1/32)} of an inch up to {fraction (3/16)} inch (0.079 cm up to 0.238 cm) is provided between the adjacent skins.

[0006] A space is incorporated into each panel to extend along the side edge of the panel. The space can illustratively be formed by a spacer positioned adjacent to the edge of the inner metal skin to be welded. This spacer, which may take various shapes and forms, extends inwardly from the edge to be welded a predetermined distance along the skin surface facing the core. The spacer also extends a predetermined distance into the core from the skin surface facing the core. Thus, when two panels are abutted together with their inner metal skins arranged in close proximity, the adjacent spacers and the two panels provide a space about and along the metal skin joint to be welded. When the weld is made at this joint, the heat produced by the weld will not damage or deteriorate the insulative core to provide offgasing. It should be understood that while a spacer is discussed in this disclosure, it is within the scope of the disclosure to utilize any means for providing a void between the joint and the insulative material. For example, the insulative material could instead be cut away to include a void, rather than using the spacer disclosed within. The spacer along each inner metal skin edge serves as a heat sink to conduct away the heat of the weld as well as an insulative gap to protect the core material from the heat of the welding.

[0007] According to the disclosure, a insulated panel is configured to connect with other insulated panels to form a thermally insulated enclosure. The panel comprises an inner metal skin facing inwardly toward the enclosure, an outer skin, and an insulative core sandwiched between the inner and outer skins. The inner metal skin has an edge, and the insulative core has an edge positioned to be in substantial alignment with the inner metal skin edge. The panel further includes a spacer extending along the edges of the inner metal skin and the insulative core. The spacer is configured to define a space extending longitudinally between the inner metal skin edge and the insulative core edge.

[0008] In another embodiment of the disclosure, a weldable wall joint comprises a first panel having a metal skin and a second panel having a metal skin, the second panel being positioned to substantially abut a portion of the first panel and define a joint therebetween. The first panel includes a first heat sink extending through the first panel alongside the joint, and the second panel includes a second heat sink configured to extend through the second panel alongside the joint.

[0009] A method of manufacturing a thermally insulative panel is also provided. The method includes the steps of positioning a first panel such that it substantially abuts a second panel and forms a weldable joint therebetween, and providing a space of preselected dimensions in each of the panels. Each of the first and second panels includes an insulative core, and the space is provided along the weldable joint and defines an area where the insulative core does not exist.

BRIEF SUMMARY OF THE DRAWINGS

[0010] The detailed description particularly refers to the accompanying figures in which:

[0011]FIG. 1 is a fragmentary view of an insulated panel seam that has been welded;

[0012]FIG. 2 is a fragmentary sectional view of one embodiment of the disclosure, showing square spacers positioned at the weldable seam;

[0013]FIG. 3 is a fragmentary cross-sectional view of another embodiment of the spacer;

[0014]FIG. 4 is a fragmentary cross-sectional view of yet another embodiment of the spacer, wherein the spacer includes a slot;

[0015]FIG. 5 is a fragmentary cross-sectional view of a “J”-shaped embodiment of the spacer;

[0016]FIG. 6 is a fragmentary cross-sectional view of another embodiment of the spacer; and

[0017]FIG. 7 is a fragmentary cross-sectional view of a panel showing the panel skin being used to form the spacer.

DETAILED DESCRIPTION OF THE DRAWINGS

[0018] In the illustrative embodiment, a wall, ceiling, or floor structure is provided comprising adjacent panels with each panel having at least one edge configured to abut against at least one edge of an adjacent panel. Each illustrative panel comprises an inner metal skin, an outer skin, and an insulative core sandwiched between the inner and the outer skins. A spacer extends fully along one edge of the panel. The spacer is configured such that when adjacent panels are abutted together and their edges of the metal skins are abutting or slightly spaced apart to provide a gap therebetween, the insulative cores are spaced from their at least one edges a distance permitting the edges to be welded without damage to the insulative cores.

[0019] When the inner metal skins are welded together along their abutting or adjacent edges, the joint between the adjacent panels is completely sealed against penetration of gas or vapor and particularly against penetration by any pathogens. Enclosures fabricated in such a manner can be held at very low temperatures and then washed and/or sterilized with live steam at very high temperatures.

[0020] A method is provided for manufacturing a thermally insulative wall, ceiling, or floor. A first panel and a second panel are configured to abut each other such that the metal skins of the panels are illustratively aligned in a plane and form a joint therebetween. An insulative core is provided for each panel, defining a space of predetermined dimensions about the weldable joint. In illustrative embodiments, a spacer is used to define the space about the weldable joint. One such spacer may have a substantially square-shaped cross-section. The spacer can be formed of extruded or rolled plastic or metal and is positioned to extend along the joint to be welded.

[0021] The joint is desirably welded such that it is sealed, and the welding does not cause offgasing or substantial heating of the insulative core. By providing a space of predetermined dimensions between the welded joint and the insulative core, offgasing of harmful vapors is substantially prevented. A distance of approximately {fraction (7/8)} inch (2.222 cm) between the weldable joint and the insulative core is illustratively provided, and is believed to substantially prevent such offgasing. However, while {fraction (7/8)} inch (2.222 cm) has been determined to be a sufficient distance for substantially preventing offgasing, it should be understood that the present disclosure could be applied with a variety of spacer widths, including from approximately {fraction (1/2)} inch to more than one inch (approx. 1.27 cm to more than 2.54 cm).

[0022] An illustrative finished wall panel joint, viewed from the inside of a refrigerated or thermally insulated room, is shown in FIG. 1. Panel 10 is welded to panel 12 with weld material 14. Inside skins 16, 18 of panels 10, 12 are each illustratively a thin metal sheet formed from 16 gauge (0.060 inch (0.152 cm) thick) 300 Series stainless steel. However, it should be understood that metal sheets of approximately 18 gauge or thicker would be sufficient for use as skins 16, 18. As shown in FIG. 1, panels 10, 12 are spaced apart a distance “C”, up to approximately {fraction (3/16)} inch (0.238 cm). It is also possible, however, to position panels 10, 12 so that the edges of the skins 16, 18 abut each other and no space is formed between them. The presently preferred spacing distance “C” is approximately {fraction (3/64)} inch, or 0.045 inch (approx. 0.114 cm).

[0023] A weld between panels 10, 12 is illustratively formed by heating weld material 14 to a high temperature such that it fills the space or joint formed between skins 16, 18. During this welding process, corners 20, 22 of panels 10, 12, respectively, achieve an elevated temperature similar to that of weld material 14.

[0024] An insulative core 24 thermally insulates panels 10, 12, as can be seen in FIG. 2. As discussed above, offgasing can occur during the welding process if the insulative core 24 is proximate to the weldable joint and corners 20, 22 and is heated to a substantial temperature as is required by the welding process. The present invention provides a space between the weldable joint and the insulative core 24 such that the insulative core 24 is protected from the elevated temperatures associated with welding, and therefore offgasing does not occur.

[0025] The welding process ideally provides an air-tight and durable seal between two abutting panels of ceiling, floor, or wall. Such an air-tight durable seal is ideally capable of repeatedly withstanding the 160° F. (71.1° C.) to 270 (132° C.) temperatures typically associated with cleaning the thermally insulated enclosure.

[0026] In one embodiment, a spacer 26 is positioned adjacent corner 20 of panel 10, as shown in FIG. 1 and in cross-sectional view in FIG. 2. Another spacer 28 is shown positioned adjacent corner 22 of panel 12. In the illustrative embodiment, spacers 26, 28 are aluminum tubes having a square cross-section, wherein the hollowed regions 30, 32 of the spacers 26, 28 are void of insulating material. Spacers 26, 28 function to provide a space between the weldable joint at corners 20, 22 and the insulative core 24. Such a space is illustratively dimensioned such that width A and depth B are both approximately {fraction (7/8)} inch (2.22 cm), as this dimension has been shown to provide sufficient distance between the weldable joint and insulative core 24. However, as mentioned above, other depths B and widths A are within the scope of the disclosure.

[0027] In another embodiment, shown in FIG. 3, spacer 26′ is configured to include a slot 34 extending lengthwise along spacer 26′. Panel 10 includes skin 16 which is configured to form corner 20 and further form a tongue 36. Tongue 36 cooperates with slot 34 to position spacer 26′ in an abutting relationship with corner 20.

[0028] Yet another embodiment of panel 10 is shown in FIG. 4, wherein spacer 26″ is substantially an inverse “J” shape. In such an embodiment, spacer 26″ cooperates with inside skin 16 surface such that neck 38 abuts an inside surface of skin 16, and leg 40 abuts tongue 36.

[0029] Panel 10 can also be formed to have a substantially straight skin 16 having an edge 42, as shown in FIG. 5, rather than a corner 20 similar to that shown in FIGS. 1-3. In such an embodiment, spacer 26 is positioned at edge 42 of skin 16.

[0030] Another embodiment is disclosed and shown in FIG. 6, wherein skin 16 is rolled to substantially form a squared edge which functions as a spacer. Illustratively, skin 16 is rolled to form a first side 44 of a dimension B, a second side 46 of a dimension A, and a third side 48 which substantially abuts the inner surface of skin 16. Such a configuration permits welding to occur at corner 20 without risk of offgasing occurring due to the space provided by the rolled skin 16.

[0031] Other configurations for spacers 26, 28 are within the scope of the invention. Importantly, a spacer 26, 28 provides a heat sink or sufficient insulative distance between a weldable joint at corners 20, 22 of panels 10, 12 and the insulative core 24, thereby preventing offgasing when the joint is welded. It should be appreciated that spacers 26, 28 can be a quarter-round, square, rectangle, or any other shape that provides the sufficient distance between corners 20, 22 and the insulative core 24. It is also within the scope of the disclosure to provide a space in the insulative core 24 without the use of spacers 26, 28. Such a configuration can be formed by cutting away the insulative core 24 in an area proximate to corners 20, 22, thereby providing a heat sink with the absence of insulative core 24.

[0032] While the disclosure is susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and have herein been described in detail. It should be understood, however, that there is no intent to limit the disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

[0033] There is a plurality of advantages of the present disclosure arising from the various features of the weldable insulated panel seam and associated method described herein. It will be noted that alternative embodiments of the weldable insulated panel seam and associated method of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of a weldable insulated panel seam and associated method that incorporate one or more of the features of the present disclosure and fall within the spirit and scope of the present disclosure as defined by the appended claims. 

1. An insulated panel configured to connect with other insulated panels to form a thermally insulated enclosure, the panel comprising an inner metal skin facing inwardly toward the enclosure, the inner metal skin having an edge, an outer skin, an insulative core sandwiched between the inner and outer skins, the insulative core having an edge positioned to be in substantial alignment with the inner metal skin edge, a spacer extending along the edges of the inner metal skin and the insulative core, the spacer configured to define a space extending longitudinally between the inner metal skin edge and the insulative core edge.
 2. The insulated panel of claim 1, wherein the spacer is a metal tube.
 3. The insulated panel of claim 1, wherein the spacer has a substantially square cross-section.
 4. The insulated panel of claim 1, wherein the spacer is approximately {fraction (7/8)} inch (2.222 cm) in depth.
 5. The insulated panel of claim 1, wherein a second insulated panel is welded to the edge of the first insulated panel, and the spacer is configured to separate the insulative core from the welded edge.
 6. The insulated panel of claim 5, wherein the spacer provides a heat sink thereby allowing the first and second insulated panels to be welded together without the insulative core becoming overheated during the welding process.
 7. The insulated panel of claim 5, wherein the spacer provides a heat sink thereby allowing the first and second insulated panels to be welded together without heating the insulative core such that it causes offgasing during the welding process.
 8. The insulated panel of claim 1, wherein the spacer defines a slot disposed along the length of the spacer.
 9. The insulated panel of claim 1, wherein the spacer is substantially “J”-shaped.
 10. The insulated panel of claim 1, wherein the inner metal skin is rolled back at the edge such that it forms the spacer.
 11. A weldable wall joint comprising a first panel having a metal skin, a second panel having a metal skin, the second panel being positioned to substantially abut a portion of the first panel and define a joint between their metal skins, a first heat sink configured to extend through the first panel alongside the joint, and a second heat sink configured to extend through the second panel alongside the joint.
 12. The weldable wall joint of claim 11, wherein the heat sink is defined by a metal tube.
 13. The weldable wall joint of claim 11, wherein the heat sink defines a substantially square cross-section.
 14. The weldable wall joint of claim 11, wherein the heat sink has a width of at least {fraction (7/8)} inch (2.222 cm).
 15. The weldable wall joint of claim 11, wherein the first and second panels include an insulative core, and the heat sink defines a space between the joint and the insulative cores.
 16. The weldable wall joint of claim 11, wherein the first and second heat sinks are defined by the metal skins of the respective first and second panels, the metal skins being formed to roll back at the joint such that they define the heat sink therebetween.
 17. A method of manufacturing a thermally insulative panel comprising the steps of positioning a first panel such that it substantially abuts a second panel and forms a weldable joint therebetween, the first and second panels each including an insulative core, and providing a space of preselected dimensions in each of the insulative cores, wherein each of the spaces is disposed along the weldable joint.
 18. The method of claim 17, wherein the space providing step comprises providing a spacer having walls that define the preselected space.
 19. The method of claim 18, wherein the spacer has a substantially square-shaped cross-section.
 20. The method of claim 18, wherein the spacer is formed from the respective panel.
 21. The method of claim 17, wherein the preselected dimension is a radius measured from the corner of each respective panel. 